c
Installation
Instructions
E-Carton Clamp High
Performance Two-Position
Relief Valve Kit 221196
This sheet provides installation instructions to remove and
replace an existing solenoid operated two-position relief valve
on Kimberly Clark electric trucks fitted with Cascade 33E
Carton Clamps. The new relief valve provides high speed
arm positioning when low clamping pressure is selected.
IMPORTANT: Verify that the relief valve is being mounted on
electric trucks with electronically-controlled auxiliary flow.
Valve 220491 may not work properly on other trucks.
WARNING: Before removing any hydraulic
lines or components, relieve pressure in the
Attachment hydraulic system. Turn the truck
off and move the auxiliary control valve lever
several times in both directions.
3
2
4
Remove old relief valve
1 Disconnect the CLAMP supply hoses from the 'T'-fittings
on the mast. Tag hoses for reassembly.
2
Disconnect and remove the existing tubing between the
'T'-fittings and the relief valve.
3
Remove the 'T'-fittings from the mast tubing and install
the two No. 8-8 straight SAE 37 ° union fittings provided
in the kit.
4
5
Disconnect the electrical wires to the solenoid.
Remove the two capscrews fastening the existing relief
valve to the mast and remove the valve.
AC0142.ill
1
5
GA0100.ill
Part No. 221195 R-1
cascadeT
For Technical Support . . .
To Order Parts . . .
Call: 1-800-CASCADE (227-2233)
Call: 1-888-CASCADE (227-2233)
OR
OR
Write: Cascade Corporation, PO Box 20187, Portland, OR 97294-0187 Write: Cascade Corporation, 2501 Sheridan Ave., Springfield, OH45505
Install new relief valve
6 Install the new relief valve on the mast using the original
9
mounting holes.
CAUTION: Check that the new capscrews are not too
long. Use the washers provided in the kit to shim the
capscrews as required.
7
8
+
Coil
(install with
part number
on top)
Diode
(banded end to
'+' or 'hot' wire)
Install the new tubing provided in the kit.
–
Reconnect the hydraulic supply lines to the bottom of
the new relief valve. Make sure the hoses are connected to the correct port (see illustration).
9
Install the diode to the solenoid coil terminals and
reconnect the electrical wires. Make sure the '+' or 'hot'
wire is connected to the same terminal as the diode's
banded end (see illustration).
6
Attachment Valve
CLAMP
P1B
Relief Valve Body
GA
UG
7
OPEN
P2B
E
OP
EN
CL
AM
Check Valve
GAUGE
Priority Flow
Control Valve
Solenoid
Operated
Valve
Low
Pressure
Relief
P1A
CLAMP
AUX
TANK
12
AC0143.ill
To AUX
TANK
port
Fixed Orifice
To CLAMP Port
(pressure line when
CLAMP auxiliary valve
lever is pulled back)
P2A
TANK
To TANK Port
8
Truck Auxiliary Valve
(CLAMP/RELEASE)
Truck
Pump
P
Logic Valve
High
Pressure
Relief
Adapter 'Tee"
Truck Relief Valve
Truck Tank
AC0148.ill
Install adapter 'tee'
10 Locate the truck low-pressure return line within the
engine compartment. In a suitable location, cut the line
and install the adapter tee supplied in the kit as shown.
11
Install the Push-Lok No. 8 JIC female fitting into one end
of the kit-supplied low-pressure return line and secure
with a hose clamp.
12
Determine the hose length required, and attach the hose
to the relief valve AUX TANK port. Route the hose to the
adapter tee, avoiding pinch and wear points. Tighten
hose fittings and hose clamps. Start the truck and cycle
the Clamp's arms several times. Check for leaks and
proper operation.
11
From relief
valve AUX
TANK Port.
From truck
auxiliary valve
Adapter 'Tee'
10
Truck low-pressure
return line
AC0150.ill
To Truck Tank
Adjust priority flow control cartridge
(If necessary)
13 If arm closing speed is noticably slow when testing the
low pressure setting, the priority flow control valve may
need adjustment.
IMPORTANT: Verify that the relief valve is being
mounted on an electric truck with electronicallycontrolled auxiliary flow. Valve 220491 may not work
properly on other trucks.
14
Loosen jam nut on priority flow control cartridge and
back adjustment screw all the way out (CCW). Turn
screw in (CW) 1 turn, then continue in with 1/4-turn
increments until arm speed is maximum. Tighten jam nut.
Low Pressure
Relief Cartridge
AC0147.ill
16
High Pressure
Relief Cartridge
AC0175.ill
15
Clamp Force Indicator
Adjust relief cartridges
15 Position a clamp-force indicator between the arms.
(Use Cascade Clamp Force Indicator, Part No. 680072.)
16
Slowly clamp on the clamp-force indicator. Hold the lever
in the CLAMP position and adjust the low-pressure relief
(upper cartridge) to 1300 lbs. clamp force. Press the
solenoid button and adjust the high-pressure relief (lower
cartridge) to 2500 lbs. clamp force. Tighten jam nuts.
WARNING: After completing any service
procedure, always test the Clamp through 5
complete cycles. First test empty, then test
with a load to make sure the Clamp operates
correctly before returning it to the job.
14
Priority Flow
Control Cartridge
Relief Valve Kit
4
0
REF QTY
9
1
2
3
4
5
6
7
7
8
9
10
11
12
GA
UG
E
8
OP
EN
CL
7
AM
P
3
AC0152.ill
! @
1
1
1
2
2
2
2
2
4
2
1
1
1
PART NO.
221196
211739
211740
211741
2348
211743
644581
651845
3564
6229
6258
220491
221197
221198
DESCRIPTION
Relief Valve Kit
Adapter Tee
Hose
Fitting, Push-Lok No. 8 JIC Female
Fitting, 8–8
Hose Clamp, No. 12
Hose Clamp, No. 16
Capscrew, 5/16–18 NC x 3-1/4 in.
Capscrew, 1/4–20 NC x 3-1/4 in.
Washer, 5/16 in.
Lockwasher, 5/16 in.
Valve Assembly
Tube
Tube
1 6
5 2
Valve Assembly
0
2
4 9
6
5
GA
UG
E
OP
EN
CL
AM
!
AC0144.ill
P
3
!
REF QTY
1
2
3
4
5
6
7
8
9
10
11
© Cascade Corporation 1999
1
1
1
1
1
1
2
1
1
1
5
PART NO.
220491
220492
224091
209049
221191
221192
221193
221194
602580
669432
604510
601377
1
8
!
7
DESCRIPTION
Valve Assembly
Valve Body
Logic Valve Cartridge
Priority Flow Control Cartridge
Check Valve Cartridge
Solenoid Valve
Coil–12 Volt
Relief Valve Cartridge
Plug, 8
Diode Assembly
Plug, 6
Fitting, 8-8
3-99
Part No. 221195 R-1